WO2013077003A1

WO2013077003A1 - Automobile interior/exterior finishing material and method for manufacturing same

Info

Publication number: WO2013077003A1
Application number: PCT/JP2012/051651
Authority: WO
Inventors: 石川　公平
Original assignee: 三井屋工業株式会社; ＢａｓｆＩｎｏａｃポリウレタン株式会社
Priority date: 2011-11-24
Filing date: 2012-01-26
Publication date: 2013-05-30
Also published as: JPWO2013077003A1

Abstract

The present invention provides an automobile interior/exterior finishing material and a method for manufacturing the same, whereby installation on a vehicle body can be facilitated and the feel of the material can be enhanced in an automobile interior/exterior finishing material in which a spacer, silencer, or the like made of a foam body is provided on one side of a base material. The present invention is an automobile interior/exterior finishing material used to cover a predetermined location of a vehicle body of an automobile, and is provided with a base material (10) formed in a predetermined shape, and a foam body (11) formed in a predetermined shape so as to be integrated with the base material (10) by insert molding using a foam resin at a predetermined location on one side of the base material (10) facing the vehicle body, the base material (10) being configured from an ornamental trim member (10A) covering the surface of a panel (BP) of the vehicle body, and the foam body (11) being configured from an acoustic absorption sheet (13) and a plurality of spacers (11A-11E) for maintaining a gap of predetermined length between the panel (BP) and the trim member (10A).

Description

Interior / exterior material for automobile and method of manufacturing the same

The present invention relates to an interior / exterior material for an automobile such as trim members such as luggage trims, luggage mats, side trims, deck trims, deck boards, door trims, and liner members such as fender liners, and a method of manufacturing the same.

Usually, a trim member or liner member, which is an interior and exterior material for an automobile, is made of a synthetic resin or non-woven fabric to correspond to the shape of an attachment location such as a body panel or door panel of an automobile or a wheelhouse or trunk room. It is obtained by molding into a three-dimensional shape (see, for example, Patent Documents 1 to 3). Further, the base material of the trim member and the liner member is formed such that the peripheral portion thereof is in contact with the body panel or the like, the wheel house, the trunk room or the like.
On the other hand, the trim member and the liner member are attached not only to the base material but in many cases, a spacer, a silencer and the like are attached on the inner surface (surface on the vehicle body side) of the base material.
That is, if it is a trim member, since the substantially central portion floats apart from the body panel etc., it is greatly bent when touched, and in order to suppress being inferior in the thin and weak texture, the body panel A spacer made of a foamed resin is interposed between them and the like (eg, Patent Document 4). In the case of a liner member, a sheet-like silencer made of a foamed resin, a non-woven fabric, or the like is joined to the inner surface of the base in order to prevent noise from entering the vehicle from the outside.

JP 2011-116190 A Unexamined-Japanese-Patent No. 2007-301889 JP, 2007-45240, A Japanese Patent Application Laid-Open No. 10-165559

However, in the above-mentioned conventional automobile interior and exterior materials, at the time of the installation work to the vehicle body, attachment of a spacer, a silencer, etc. to a base material becomes complicated and time consuming, and the spacer and the silencer are attached There is a problem that the mounting operation is complicated without corresponding to the shape of the above.
That is, usually, a block-like foam is used for the spacer, and the operator cuts the foam into an appropriate size and applies an adhesive to the foam, one by one. A series of operations, such as bonding to a substrate while aligning, is performed manually. In addition, a fiber sheet is usually used for the silencer, and a worker manually cuts the fiber sheet into an appropriate size and manually bonds or sews it to a substrate.
In the case where the foam or fiber sheet is in contact at the attachment point, the area where the foam or fiber sheet is in contact is a curved surface, a reinforcing member or a unit is attached, or a harness is installed. There is. If the unevenness is small, it can be coped with by elastically deforming the foam or the fiber sheet, but if it can not be coped with by the elastic deformation, the trim member is attached to prevent appearance defects such as the trim member floating from the vehicle body. The post-processing such as manually scraping or re-cutting the foam or the fiber sheet is required so as not to interfere with the above.
Furthermore, if it is intended to avoid reinforcements, units and harnesses, or try to simplify the installation work to reduce the number of attachment points of the foam, the spacing between the attachment points of the foam becomes large. , Part of the part left floating from the body panel etc. will be created. Since such a partial location has lower surface rigidity as compared to the periphery of the location where the foam is attached, the deflection when touched is obviously larger than the location where the foam is attached, which causes deterioration of the texture. There was a problem that.
The present invention has been made focusing on the problems existing in the above-mentioned prior art, and the object of the present invention is an interior and exterior for an automobile provided with a spacer, a silencer and the like made of foam on one surface of a substrate. It is an object of the present invention to provide an automobile interior / exterior material and a method of manufacturing the same, which can simplify installation work to a vehicle body and improve texture.

In order to achieve the above object, the invention of the interior and exterior material for an automobile according to claim 1 is an interior and exterior material for an automobile, which is used to cover a predetermined portion of a vehicle body of an automobile. A base material, and a foam formed in a predetermined shape so as to be integrated with the base material by insert molding using a foamed resin at a predetermined location on one surface of the base material facing the vehicle body The point is that
The invention according to claim 2 is the invention according to claim 1, wherein the base material constitutes a trim member that covers and decorates the surface of the panel of the vehicle body, and the foam is The gist of the present invention is to constitute a spacer for keeping the distance between the panel and the trim member at a predetermined length.
In the invention according to claim 3, in the invention of the interior and exterior material for an automobile according to claim 2, the foam has a plurality of the spacers and sound absorption integrally formed with the spacers between the spacers. The gist of the present invention is to constitute a sheet.
The invention according to claim 4 is the invention of the interior and exterior material for an automobile according to claim 1, wherein the base material constitutes a liner member that covers and protects a predetermined portion of the vehicle body, and the foam is: The gist of the present invention is to constitute a sound absorbing sheet that suppresses the ingress of sound into the automobile through the liner member.
The invention of the method of manufacturing an automobile interior and exterior material according to claim 5 is a method of manufacturing an automobile interior and exterior material according to any one of claims 1 to 4, which receives the above-mentioned base material A first step of fixing to a jig, a second step of holding the base between the holding jig provided with a forming recess so as to face one surface of the base, and the receiving jig The third step of injecting a resin solution into a cavity surrounded by the inner surface of the molding recess and one surface of the base, and curing the resin solution after foaming flow in the cavity; And a fourth step of integrally molding the foam on one side.

[Function]
In the interior and exterior material for automobiles of the present invention, a foam is integrally formed on one surface of a base material by insert molding using a receiving jig and a holding jig provided with a molding recess as a molding die. There is. Therefore, the interior and exterior material for a vehicle according to the present invention does not have to be attached manually while paying attention to the mounting location of the foam on one surface of the base material during the attachment operation. In addition, the foam can be made into any desired shape by adjusting the shape of the molding recess of the holding jig used as a molding die, and it is necessary to adjust the shape by post-processing Absent. As a result, the mounting work to the vehicle body becomes simple. Furthermore, since the interior and exterior material for a vehicle according to the present invention can have the foam in a desired shape and position according to the mounting location, the foam has a shape and position that suppresses a partial reduction in surface rigidity. The texture can be improved by reducing the bending when touching.
Further, according to the method of manufacturing an interior and exterior material for a motor vehicle of the present invention, when there is a design change in the vehicle body of the motor vehicle, it has an advantage of being easy to cope with this. That is, in the conventional case, it is necessary to change the production process in order to change the mounting order and the number of mounting according to the design change, but in the case of the manufacturing method of the present invention, the pressing jig provided with the forming recess There is no need to change the production process only by replacing it. In addition, according to the manufacturing method of the present invention, the density of the foam can be easily changed by changing the injection amount of the resin liquid into the cavity, so that the surface rigidity according to the change of the density, In other words, the deflection when touched can be easily adjusted, and the texture can be further improved.
The above-mentioned automobile interior and exterior material is applied to an automobile trim comprising a trim member as a base material and a spacer as a foam, and an automobile liner comprising a liner member as a base material and a sound absorbing sheet as a foam. Is desirable.
Moreover, the said interior and exterior material for motor vehicles can unify and provide the spacer and sound absorption sheet which comprise a foam on one surface of a base material. When the spacer and the sound absorbing sheet are integrally provided, the mounting operation to the vehicle body is extremely simplified as compared with the case where the spacer and the sound absorbing sheet are individually provided.

〔effect〕
According to the present invention, in the interior and exterior material for an automobile provided with a spacer, a silencer and the like made of foam on one surface of the base material, the interior for an automobile can be simplified and its texture can be improved. An exterior material and a method of manufacturing the same can be provided.

(A) is a perspective view from the surface side showing the interior / exterior material for a car of the embodiment, (b) is a perspective view from the back side, and (c) is a cross-sectional view of a state of being mounted on a vehicle body. Sectional drawing which shows the 1st process of manufacture of the interior-and-exterior material for motor vehicles. Sectional drawing which shows the 2nd process of manufacture of the interior-and-exterior material for motor vehicles. Sectional drawing which shows the 3rd process of manufacture of the interior-and-exterior material for motor vehicles. Sectional drawing which shows the 4th process of manufacture of the interior-and-exterior material for motor vehicles. Sectional drawing which shows the interior / exterior material for motor vehicles of another form. Sectional drawing which shows the interior / exterior material for motor vehicles of another form.

Hereinafter, one embodiment which materialized the interior and exterior material for cars of the present invention is described.
As shown in FIGS. 1 (a) to 1 (c), the interior and exterior material for an automobile includes a base 10 and a foam 11 provided on the back of the base 10.
The base 10 is formed in a predetermined shape in order to cover a predetermined portion of a vehicle body of an automobile. The base material 10 of the present embodiment constitutes a luggage trim 10A for covering a vehicle body panel BP exposed to the side in a luggage room of a car.
The foam body 11 is formed on the back surface of the base material 10 in a predetermined shape by insert molding so as to be integrated with the base material 10. The foam body 11 of the present embodiment comprises

spacers

11A, 11B, 11C, 11D, 11E for keeping a distance between the vehicle body panel BP and the luggage trim 10A at a predetermined length, and a sound absorbing sheet 13. There is.

Among the spacers 11A to 11E, the

spacers

11A and 11B provided on the upper part of the luggage trim 10A are provided with a harness H in the vicinity of the contact portions of the

spacers

11A and 11B on the vehicle body panel BP. Therefore, it is formed so as to have a shape that does not hit the harness H.
On the other hand, of the spacers 11A to 11E, the

spacers

11C and 11D provided at the lower part of the luggage trim 10A are the wheel house of the vehicle panel BP which is the contact portion of the

spacers

11C and 11D and are inclined surfaces. Therefore, it is formed to have a shape corresponding to the contact portion.
Further, the spacers 11A to 11E are formed on the inner surface of the luggage trim 10A at positions where their intervals are substantially equal, and the partial reduction of the surface rigidity of the luggage trim 10A is prevented to prevent The texture is improved by reducing the deflection when the luggage trim 10A is touched from the outer surface side.
The sound absorbing sheet 13 is formed integrally with the spacers 11A to 11E with the spacers 11A to 11E. The sound absorbing sheet 13 reduces the noise by exhibiting a buffer sound absorbing function with respect to the noise that tends to get into the car.

The substrate 10 is made of, for example, an olefin resin such as polypropylene or polyethylene, an ester resin such as polyethylene terephthalate, a thermoplastic resin such as acrylonitrile-butadiene-styrene copolymer resin (ABS resin), or a non-woven fabric. It is formed in a predetermined shape by a molding method such as injection molding, vacuum / pressure forming, heating press molding or the like.
The foam 11 is formed by foaming a resin solution, for example, using a foam resin such as polyurethane foam, polystyrene foam, polyolefin foam, phenol resin foam, polyvinyl chloride foam, silicone foam, etc. It is formed. Among the foamed resins, polyurethane foam is easy to obtain, is suitable for insert molding by cast foam molding such as molding foaming and injection foaming, and can be suitably bonded (adhered) to the above-mentioned base material 10, desirable.
As the polyurethane foam, it is desirable to use a two-component type in which liquid A consisting mainly of a polyol component and liquid B consisting of an isocyanate component are mixed and used. This is because the use of a two-component polyurethane foam can suitably adjust the properties such as heat resistance, sound absorption, hardness (elasticity) and adhesiveness.
When the foam 11 is formed using the polyurethane foam, its density is preferably set to 10 to 100 kg / m ³ , and 30 kg / m ³ if its main purpose is to use as a spacer. It is more preferable to set to 100 kg / m ^3, and it is more preferable to set 10 to 20 kg / m ³ if the main purpose is to use as a sound absorbing sheet. If the density is less than 10 kg / m ³ , the foam 11 may be too soft to be used as a spacer, and the distortion when the luggage trim 10A is touched from the outer surface side may be large and the texture may be deteriorated. . When the density exceeds 100 kg / m ³ , the foam 11 is too hard to be used as a sound absorbing sheet, and a sufficient cushioning sound absorbing function can not be exhibited, and noise is generated by reflecting sound. There is a risk of causing

The manufacturing method of the said interior and exterior material for motor vehicles is demonstrated.
In the manufacture of the interior and exterior material for an automobile, a receiving jig 50 for fixing the base 10 and a pressing jig 51 for molding the foam 11 are used.
As shown in FIG. 2, the receiving jig 50 is a fixing recess having a shape corresponding to the surface of the base 10 (in the case of this embodiment, the luggage trim 10A) on the upper surface thereof to fix the base 10. 50a is formed. The base 10 fitted in the fixing recess 50 a is fixed to the receiving jig 50 such that the back surface on which the foam 11 is formed is directed outward.
As shown in FIG. 3, in the pressing jig 51, a molding recess 52 is formed on the lower surface which is to face the back surface of the base 10 fixed to the receiving jig 50. The molding recess 52 is for molding the foam 11, and corresponds to the

recesses

52A, 52B, 52C formed in a shape corresponding to the shape of the spacers 11A to 11E and the shape of the sound absorbing sheet 13. The concave portions 52D are formed integrally with each other and the concave portions 52D are formed integrally (in FIG. 3, the concave portions corresponding to the

spacers

11A and 11E are omitted). Further, on the lower surface of the pressing jig 51, a fixing convex portion 51b having a shape corresponding to the back surface of the base 10 is provided so that the base 10 can be held between the receiving jig 50 and sandwiched. It is formed.
A plurality of

injection holes

53A, 53B and 53C are formed on the upper surface of the pressing jig 51 so as to communicate with the

recesses

52A, 52B and 52C inside the forming recess 52, respectively. The resin solution can be injected from the injection hole 53A to the inside of the recess 52A, from the injection hole 53B to the inside of the recess 52B, and from the injection hole 53C to the inside of the recess 52C, and further, each of the

recesses

52A, 52B, 52C. The resin liquid can be injected into the recess 52D from the inside. A handle 51d is provided on the upper surface of the pressing jig 51, and the pressing jig 51 can be easily moved with respect to the receiving jig 50 by using the handle 51d.
Examples of the material used for the receiving jig 50 and the pressing jig 51 include thermoplastic resins, synthetic resins such as thermosetting resins, metals such as iron, copper and aluminum, gypsum, and the like. Synthetic resins are desirable from the viewpoints of being easy to correspond to the shape of the above, easy to handle and transport, etc. Among them, thermosetting resins are more desirable because strength and durability are suitable.

The base 10 is fixed to the receiving jig 50 in the first process of manufacturing the interior and exterior material for a car. The luggage trim 10A, which is the above-mentioned base material 10, is formed in advance in a process different from the production (see FIG. 2).
In the second process of manufacture, the pressing jig 51 is attached to the base 10 fixed to the receiving jig 50, and the base is interposed between the receiving jig 50 and the pressing jig 51. The material 10 is held (see FIG. 3).
In the third process of manufacture, the resin liquid is inserted into the cavity 54 surrounded by the inner surface of the molding recess 52 of the pressing jig 51 and the back surface of the base 10 through the injection holes 53A, 53B, 53C. Is injected (see FIG. 4).
In the fourth step of the production, the resin solution injected into the cavity 54 is hardened after foaming and flowing, whereby the spacers 11A to 11E and the sound absorbing sheet 13 which are constituted by the foam 11 are made of the substrate 10. It is integrally molded on the back surface (see FIG. 5).
After the fourth step, the holding jig 51 is removed to obtain the interior and exterior material for an automobile.

In the third step, an injection gun (not shown) is used to inject the resin liquid. When polyurethane foam is used as the material of the foam 11, in order to foam polyurethane, a method of mechanically foaming by adding a reactive foaming agent or an inert foaming agent to the raw material mixture of the polyurethane is adopted Is desirable. As a method of mechanically foaming, a non-floss method in which a raw material mixture is discharged in a liquid form from a mixing head and the liquid discharge is creamed and then foamed, and a floss method in which a raw material mixture is discharged in a foam form from a mixing head The spray foaming method etc. which spray a raw material mixture by compressed air are applied. The density of the foam 11 is adjusted by adjusting the injection amount of the resin liquid in the third step.
In the fourth step, curing of the resin solution may be performed by compression and heating as necessary, or the resin solution may be foamed and free-cured by free forming. When polyurethane foam is used as the material of the foam 11, it may be bonded to the substrate 10 according to the tackiness of the polyurethane, or a hot melt adhesive, urethane adhesive, etc. on the back of the substrate 10 in advance. An adhesive may be applied and bonded by the adhesive.

The interior and exterior material for a motor vehicle of the present invention is not limited to the configuration shown in the above embodiment, but may be modified as follows.
The density of the foam 11 may be partially changed by dividing the cavity 54 into a plurality of spaces and changing the injection amount of the resin liquid into each space. For example, partition walls are provided between the recess 52A and the recess 52B and between the recess 52B and the recess 52C in the inside of the forming recess 52 of the pressing jig 51, and the interior of the cavity 54 is formed by the partition wall. The spacer 11B is divided into two spaces, and the injection amount of the resin liquid to the space having the recess 52B among the three spaces is smaller than the injection amount of the resin liquid to the space having the recess 52A and the recess 52C. The density of the spacer 11D can be reduced compared to the density of the spacer 11C.
When the density of the foam 11 is partially changed by changing the injection amount of the resin liquid as described above, in the third step of production, the same injection gun is used to inject the resin liquid into each space. Only the injection amount of the resin solution may be changed, or different injection guns may be used in each space.
When the inside of the molding recess 52 is divided into a plurality of spaces as described above, the spacers 11A to 11E formed of the foam 11 and the luggage trim 10A formed of the base 10 are integrated. If the sound absorbing sheet 13 formed by the foam 11 and the luggage trim 10A formed by the base 10 are integrated, the inside of the forming recess 52 is formed into a spacer. The spacers 11A to 11E and the sound absorbing sheet 13 may be separately formed by dividing the space into a space for forming the sound absorbing sheet.

As shown in FIG. 6, in the interior and exterior material for a motor vehicle, only the spacers 11A to 11E may be constituted by the foam body 11. The manufacture of the interior and exterior material for a motor vehicle can be coped with by forming a plurality of forming recesses 52 for forming the spacers 11A to 11E in the pressing jig 51.
As shown in FIG. 7, the interior and exterior material for an automobile may constitute the fender liner 20A, which is a liner member, by the base material 10, and may constitute the spacer 21A and the sound absorbing sheet 21B by the foam body 11. The fender liner 20A is intended to prevent pebbles, gravels and rainwater from rising into the interior of the vehicle by covering the upper portions of the wheels in the wheel house of the automobile. Further, the sound absorbing sheet 21A is for suppressing noise such as road noise due to the wheel and chipping noise generated due to collision of pebbles with the fender liner 20A from entering the automobile through the fender liner 20A. .

As the above-mentioned trim member, luggage mat, side trim, deck trim, deck board, door trim, door opening trim, etc. may be configured by the base material 10. Further, as the liner member, a head lining that covers the ceiling of the vehicle interior, a floor lining that covers the floor of the vehicle interior, or the like may be configured as the liner member. The interior and exterior materials for automobiles may be dash silencers, engine hood silencers, trunk lid silencers, bumper cores, mud guards, body side moldings, and the like.

In the interior and exterior material for automobiles of the present invention, spacers and silencers made of foam are integrally formed on one surface of the base material, so that the mounting work to the vehicle body can be simplified. It is available above.

DESCRIPTION OF REFERENCE NUMERALS 10 base material 10A luggage trim 20A fender liner 11

foam

11A, 11B, 11C, 11D, 11E spacer 13 sound absorbing sheet 21A spacer 21B sound absorbing sheet 50 receiving jig 51 holding jig 51a molding recess

Claims

An interior and exterior material for a car that is used to cover a predetermined part of the car body of the car,
A substrate formed in a predetermined shape,
as well as,
A foam formed in a predetermined shape so as to be integral with the base material by insert molding using a foamed resin at a predetermined location on one surface of the base material facing the vehicle body;
An interior and exterior material for an automobile, comprising:
The base material constitutes a trim member that covers and decorates the surface of the panel of the vehicle body,
The automobile interior / exterior / exterior material according to claim 1, wherein said foam constitutes a spacer for keeping the distance between said panel and said trim member at a predetermined length.
The interior and exterior material for an automobile according to claim 2, wherein the foam comprises a plurality of the spacers and a sound absorbing sheet integrally formed with the spacers between the spacers.
The base material constitutes a liner member that covers and protects a predetermined portion of the vehicle body,
The automobile interior / exterior material according to claim 1, wherein the foam constitutes a sound absorbing sheet that suppresses the ingress of sound into the automobile through the liner member.
It is a manufacturing method of the interior and exterior material for cars according to any one of claims 1 to 4,
A first step of fixing the substrate to a receiving jig;
A second step of holding the base between the holding jig and a holding jig provided with a molding recess so as to face one surface of the base;
A third step of injecting a resin liquid into a cavity surrounded by the inner surface of the molding recess and one surface of the base;
A fourth step of integrally molding the foam on one surface of the base material by curing the resin liquid after foaming flow in the cavity;
The manufacturing method of the interior-and-exterior material for motor vehicles characterized by comprising.